Method for the manufacture of cemented pile fabrics



Aug. 11, 1936. p 5, 5M|TH 7 2,051,010

METHOD FOR THE MANUFACTURE OF CEMENTED PILE FABRICS Originaal Filed May5, 1932 6 Sheets-Sheet l P. 5. SMITH Aug. 11, 1936.

METHOD FOR THE MANUFACTURE OF CEMENTED PILE FABRICS Original Filed May5, 1932 6 Sheets-Sheet 3 Aug. 11, 1936. P. 5. SMITH 2.051fi10 METHOD FORTHE MANUFACTURE OF CEMENTED FILE FABRICS Original Filed May 5, 1932 6Sheets-Sheet 4 P. s. SMITH 2,051,01

METHOD FOR THE MANUFACTURE OF CEMENTED PILE FABRICS Aug. 11, 1936.

6 Sheets-Sheet .5

Original Filed May 5, 1932 Au 11, 1936. P. 5. SMITH msmm METHOD FOR THEMANUFACTURE OF CEMENTED PILE F 'ABRICS Original Filed May 3, 1952 6Sheets-Sheet s ICEMENT BASE FABRIC |''|CMENT BASE FABRIC l IVULOANIZINGI SPLI T TIN G SEATING :R: NG [rjjej mmj lsjjjnj mains] [SIHEARINGI] 3Patented Aug 11, 1 936 METHOD FOR THE ACTUBE OF CEIWENTED PILE FABRICSPaul S. Smith, Cambridge, N. Y., assignor to Ralph S. Allen, Detroit,Mich.

Original application May 3, 1932, Serial No. 608,999. Divided and thisapplication January 2, 1934, Serial No. 705,009

'1 Claims. (01. 154-2) My invention relates to a new and improved methodfor the manufacture of cemented pile fabric, and this application is adivision of my pending application Serial No. 608,999, filed May 3,1932, for Method and apparatus for the manufacture of cemented pilefabric. My invention relates, in general, to an improved method for themanufacture of that type of pile fabric, in.

which the fibers forming the pile are attached to a backing fabric by acementing material.

It has long been known that pile fabric may be manufactured by cementingthe fibers forming the pile to a backing sheet or fabric, and the usualpractice has been to attach such fibers to the backing sheet in loopedform, with the loop portions of the pile fibers cemented to the backingsheet. Such fibers may be applied either in the form of. yarn, or asunspun fibers. The principal object of my invention is to provide animproved method for making cemented pile fabric, which can be carriedout at a lower cost of manufacture than methods heretofore proposed orused.

A further object of my invention is to provide a an improved method forproducing a cemented pile fabric, by which the speed of production canbe greatly increased over methods heretofore employed.

A further object of my invention is to provide a method which willproduce a cemented pile fabric of improved character, the surface ofwhich will be free of any ripple eifect due to the method of itsproduction, avoiding the appearance of wire-marks characteristic ofcertain types of cemented pile fabrics.

It is desirable to be able to produce cemented pile fabrics of differingcharacteristics, that is to say, differing in the density of the fiberper linear unit of measurement of the fabric and it is an importantobject of my invention to provide a method having considerableflexibility in producing cemented pile fabric having such difieringcharacteristics, that is to say, a method which, by relatively simpleand inexpensive adjustments, can be caused to produce pile fabrics ofdifiering pile density.

The attaching of the pile to the backing sheet may involve rubberizingand vulcanizing operations and it is an object of my invention toprovide a method in which the pressure is exerted against a yieldingbody of material under treatment, as distinguished from prior machinesand methods in which the vulcanizing pressure is exerted against hardand relatively incompressible separator plates upon and about which thematerial is formed.

Further objects, and objects relating to details of construction andeconomies of operation will definitely appear from the detaileddescription to follow. In one instance, I accomplish the objects of myinvention by the particular steps of procedure set forth in thefollowing specification. My invention is clearly defined and pointed outin the accompanying claims. A preferred apparatus for carrying out theseveral steps constituting the method of my invention is illustrated inthe accompanying drawings, forming a part of this specification, inwhich:-

Figures 1 and la, taken together, constitute a diagrammatic view of anassemblage of equipment by which the several steps of my improved methodmay be carried out;

Fig. 2 is a diagrammatic representation, partly in cross section, in aplane at right angles to the web or hat of unspun fibers, of certainmechanism which may be employed in one step of my improved method as ameans for continuously looping the said web of unspun fibers about theseparating strips;

Fig. 3 is a similar view representing a modified form of apparatus whichmay be employed for continuously looping a warp of spun yarns about theseparating strips, instead of a web or bat of unspun fibers;

Fig. 4 is an end elevation of certain of the mechanism shown in sectionin Fig. 2 for carrying out the continuous looping step of my method,illustrating the mechanical elements for imparting the required motionto said mechanism;

Fig. 5 is a side elevation, partly broken away, of the mechanism shownin Fig. 4, looking from the right hand side thereof;

Fig. 6 is a top plan view, partly broken away,

' of the mechanism shown in Figs. 4 and 5;

Fig. 7 is a side view of one of the plaiting bars which may be used inthe step of continuously looping or plaiting the fibers about theseparator strips;

Fig. 8 is an end view of the plaiting bar shown in Fig. 7;

Fig. 9 is a view in side elevation illustrating certain apparatus whichmay be employed to carry out the step of forming the separator stripsand supplying them to the plalting bars;

Fig. 10 is a diagrammatic top plan view of said mechanism illustratingthe formation of the separator strips from a web of material;

Fig. 11 is an enlarged view in cross section, taken in a plane at rightangles to that of the plaited structure, showing a portion of theapparatus which may be employed to carry out the step of continuouslylooping a fibrous web about the separator strips;

Fig. 12 is an end view, partially diagrammatic, of apparatus which maybe employed for carrying out that step of my method consisting ofcementing base fabrics to opposite faces of the plaited structure formedby plaiting a fibrous web about the separator strips;

Fig. 13 is a view in side elevation of the parts shown in Fig. 12illustrating also diagrammatically, one of two identical rubberizingmechanisms for applying rubber latex or a compound thereof to theopposite faces of the plaited structure;

Fig. 14 is a diagrammatic representation of apparatus which may beemployed for carrying out that step of my method consisting of splittingthe plaited structure along a plane parallel to that of the basefabrics, to form two webs of cemented pile fabric;

Fig. 15 is a diagrammatic .view, analogous to that of Fig. 13, showingmeans which may be employed for temporarily supporting the plaitedstructure at the beginning of the plaiting operation; and

Fig. 16 is a fiow sheet indicating the various consecutive steps whichmay be employed in the complete manufacture of cementedpile fabric inaccordance with my improved method.

In the drawings, the same reference numerals indicate the same partsthroughout the several views.

In general, the method of making cemented pile fabric in accordance withmy invention consists in continuously looping, either a warp of spunyarns, or a web or bat of unspun fibers, about a series of separatorstrips, so that the warp will pass around the edge of one strip, overthat strip, and around the opposite edge of the strip next above it,over the face of that strip and around the opposite edge of the one nextabove it, and so on, thus folding the fibrous warp, alternately, aboutthe spaced separator strips. The function of these separator strips isto hold the fibers in proper relation to each other while they arecemented to a backing sheet or sheets and, in order to facilitate theremoval of these separator strips at a certain stage in manufacture, Ipropose to form them of a material which can be severed readily. Theplaited structure, comprising these separator strips and the fiberscontinuously looped about them, is confined, and, while so confined, acementing material is applied to opposite faces thereof. This cementingmaterial is then dried and webs of cemented base fabric are applied toopposite faces of the plaited structure and vulcanized thereto, afterwhich the plaited structure is split longitudinally, giving twoidentical webs of cemented pile fabric, each of which may be subjectedto a beating operation for the purpose of removing any remainingseparator strips, a combing or tigering operation to arrange the pilefibers in substantial parallelism, and a final shearing operation bywhich such fibers are cut to give a pile of the desired depth.

Any suitable apparatus may be employed for carrying out the severalsteps which constitute my improved method but I have found that themethod may be most eificiently employed by the use of mechanisms forcarrying out the several steps, as follows. For the step of continuouslylooping a warp of spun yarns, or a web or bat of unspun fibers about theseparator strips to form a plaited structure, I propose to use aplaiting frame having thereon a pair of plaiting bars. Associated withthis plaiting mechanism, I propose to provide means for feeding theseparator strips into place and, preferably, such means is so associatedwith the plaiting bars that these bars, in their movement to and fro,will place the separator strips in required position. As alreadysuggested, I propose to form the separator strips of a readily severablematerial, such as chip-board, and, if desired, I may employ a mechanismfor forming such separator strips from a continuous web of the material,which forming means are, so associated with the plaiting mechanism thatthe latter may complete the formation of the separator strips andposition the formed strips in the plaited structure. In carrying outthat step consisting of continuously looping the fibrous web about theseparator strips to form a plaited structure, I prefer to use apparatusincluding a pair of spaced plates, defining a passage in which theplaited structure as formed is confined and advanced, the mechanismbeing so arranged that, as the plaited structure is formed, it entersbetween these confining plates, and is held between them during thesucceeding step of the method. For'carrying out that step of my methodconsisting in cementing webs of base fabric to opposite faces of theplaited structure, I prefer to use rubberizing mechanism, by whichrubber latex or a compound thereof may be applied to opposite faces ofthe plaited structure, while confined between said plates, a dryingmechanism for drying this cemented material, and a mechanism by whichbacking sheets of cemented fabric are applied to opposite faces of theplaited structure. The vulcanizing and consolidating step of my improvedmethod, may be carried out by a vulcanizing and consolidating press, inwhich the plaited structure is submitted to pressure, after the cementedbacking sheets have been applied to opposite faces of the plaitedstructure, to consolidate and vulcanize the backing sheets thereon. Iprefer to use in this step a press which is so organized that the pressplatens will travel with the fabric for a short distance, while thepressure is being applied thereto. I propose to use a splittingmechanism by which the plaited structure is split longitudinally along aplane parallel to opposite faces of the plaited structure, to form twocontinuous webs of cemented pile fabric. This splitting mechanism maywell take the form of a band-knife, and, in splitting the plaitedstructure, it cuts not only the fibers, but also the separator strips,which then drop out or are removed in the subsequent operations.

The first step of my improved method consists in continuously looping afibrous web about a series of separator strips to form a plaited structure and mechanism by which this step may be carried out is shown at theupper end of Fig. l and also in Figs. 2 to 8, inclusive.

Referring to Fig. 2, a web or bat IIII, of unspun fibers, is deliveredto the mechanism from a roll I00, in which roll the web or bat is woundspirally under tension on a shell I03, in alternate layers with awrapper I02, which may be of any suitable fabric, but is preferably ofholland cloth. The roll I03 is supported by the rollers I04 and I05,which are driven in the proper direction to unwind the roll I00, anddeliver the web IOI therefrom to the plaiting mechanism. The wrapper I02is taken off from the roller I05 to the shell I06, upon which saidwrapper is wound. As already stated, my method is applicable also to theformation of pile fabric from fibers in the form of a warp of spunyarns, which I prefer to use, and, in that case, the mechanism shown inFig. 3 may be employed for delivering the warp to the plaitingmechanism. As shown in Fig. 3, a warp of yarns I01 is wound on a Warpbeam I08, and led therefrom over tension bars I09, H0, and III, andthrough a spacing or separating comb H2, of usual form, to the plaitingmechanism. Wherever, in this specification and the appended claims, Irefer to a fibrous web, I wish to be understood as including both a webor bat of unspun fibers and a warp of threads or yarns.

The plaiting mechanism comprises a frame H3, carrying a pair of plaitingbars H4 and H5, said frame being so supported, guided and actuated, thatthe lower edges of the plaiting bars move in the curved paths indicatedby dotted lines in Fig. 2. The purpose of this plaiting mechanism is toplace the separator strips 99 in position, successively, and tocontinuously loop or fold the warp of yarns I01, or the web of fibersIOI, back and forth about these separator strips, as shown moreparticularly in the enlarged view, Fig. 11. The frame H3, carrying theplaiting bars H4 and H5, is guided at opposite edges in the guides H6and H1. Arms I21 and I29 extend upwardly from the guides H6 and H1 andare mounted in the vertical guides I3I, I32 and I35, I36, respectively.Arms I28 and I30 extend downwardly from the guides H9 and H1 and areguided for vertical movement between the guide members I33, I34 and I31,I38, respectively. Pins I39 and I40, on the lower ends of arms I28 andI30, carry the rollers I4I and I42, which ride in the cams I43 and I44,respectively, said cams being fixed on the shaft I45. Accordingly, theguides H and H1 are mounted so as to have a vertical movement, whichmovement is imparted thereto by cams I43 and I44, as the shaft I45revolves. The plaiting frame H3 is mounted for horizontal movement withrespect to the guides H6 and H1, and such movement is imparted theretoby the eccentrics I24 and I25, mounted on shaft I20, and connected tosaid frame by the arms I22 and I23, which are connected by pins I20 andI2I in the forks H8 and H9, fastened to the plaiting frame H3, as shownin Fig. 6. Thus, as shafts I26 and I45 revolve, the plaiting frame H3will be subjected to a compound motion, resulting from the slidingmotion of the frame H3 in the guides H6 and H1, which are simultaneouslysubjected to a vertical movement, the cams being so designed and mountedthat the frame H3 will have such motion that the lower edges of the barsH4 and H5 will travel along the curved paths indicated by dotted linesin Fig. 2, so that first one of the plaiting bars and then the otherwill be brought to, and removed from, alinement with the entrance end ofthe passage defined by the confining plates, within which the plaitedstructure is to be formed and advanced. It will be seen from Fig. 2 thatthe web of unspun fibers IOI passes between the plaiting bars H4 and H5,so that the movement of said bars to and fro carries this web from oneedge to the other of the entrance to the passage between the confiningplates. In case this method is used with a warp of yarns, employing themechanism shown in Fig. 3, the warp is likewise passed between theplaiting bars H4 and H5.

Referring to Fig. 2, the plaiting bar H4 has just moved the web IOIacross the upper surface of a separator strip 99, and deposited anotherseparator strip above said web, and the plaiting bar I I5, as will beexplained later, has just picked up a separator strip 99, for thepurpose of carrying it into position. As the frame H3 moves to the left,Fig. 2, the plaiting bar H4 moves to the dotted line position shown,following the curved path indicated, but leaving the separator strip inposition above the web I0 I, and the plaiting bar H5, carrying anotherseparator strip 99, which it has picked up, moves to the left, as shownby dotted lines, thus folding the web I M over the upper surface of theseparator strip 99, deposited by the plaitlng bar H4, and depositing theseparator strip carried by the bar H5 on top of this folded portion ofweb IOI. Thus, as

the frame I I3 moves to and fro, the bars H4 and vide a mechanism forforming these strips, which co-operates with the plaiting mechanism, sothat each strip, as formed, is taken by the plaiting mechanismandpositionedin the plaited structure. The strip-forming mechanism isillustrated in Figs. 9 and 10 and it will be understood that therewillbe two of these mechanisms provided, one at the right of themachine, as shown in Fig. 1, cooperating with plaiting bar H5, and asimilar mechanism at the left co-operating with and delivering strips tothe plaiting bar H4. A web 286 of material, such as chip-board, fromwhich the strips are to be formed, is delivered to the strip-formingmechanism, and is clamped and advanced with an intermittent movement.While passing through the strip-forming mechanism, a knife forms atransverse slit in the web, leaving portions of the web at the edgesthereof unseve'red, however. As the plaiting bar H5 descends to pick upa separator strip, knives carried thereby complete the severance of theend portions of the separator strip. The plaiting bar I I5 then picks upthe severed strip, and, in its return movement, carries it to positionin the plalted structure, the remaining edge portions of the web beingcarried off from the strip-forming mechanism.

A clamp bar 281 is mounted between the guides 288 and 289 for verticalmovement, said clamp bar being located below the web 280. A similarclamp bar 290, above the web, is guided for vertical movement betweenthe stationary guides 29I and 292, and its position with reference toclamp bar 281 may be adjusted by screws 293, in a supporting bar 294,and threaded into the clamp bar 290. Spiral springs 295 surround theadjusting screws 293 and are interposed between the stationarysupporting bar 294 and the clamp bar 290. Rocker arms 290, pivoted onthe shaft 291, each have one end engaging the lower surface of the clampbar 201, while the opposite ends of said rocker arms carry rollersbearing on cams 290, fixed on shaft 299. It will be seen that, as thecams revolve with the shaft, the rocker arms 296 will be intermittentlyactuated to move the clamp bar 281 upwardly, thus clamping the web 296between the bars 281 and 290, and holding it against movement for aperiod determined by the contour of the cams 298. A clamp bar 300, belowweb 286, is vertically movable between guides 302 and 303, which areintegral with slides 304 which fit closely in stationary U-shaped guides305. A clamp bar 306, above web 286, is vertically movable between theguides 302 and 303, and may be adjusted with reference to the clamp bar300 by screws 301, which extend through supporting bar 308 and arescrewed into the bar 306. Spiral springs 309 surround the screws 301 andare interposed between the bar 308 and the clamp bar 306. Verticalmotion is intermittently imparted to the clamp bar 300 by cams 311mounted on the shaft 299 and engaging rollers 310 mounted on the lowersurface of the clamp bar 300. The slides 304, which carry the clamp bars300 and 306, are intermittently reciprocated by the rocker arms 312pivotally mounted on the rocker shaft 291, in engagement with the endsof slides 304. These rocker arms 312 are actuated by rollers 313 ridingon cams 314 mounted on the shaft 299. Stationary lugs 315 are providedwith pins 316 which slidably fit in recesses 3 I 1 formed in the slides304. Spiral springs 318 surround the pins 316 and are interposed betweenthe lugs 315 and the slides 304. Thus, the cams 314, as the shaftrevolves, will rock the rocker arms 312 and press the slides 304 to theleft, compressing the springs 3| 8, as viewed in Fig. 9, and, as soon asthe high spots of the cams 311 and 314 have passed the rollers 310 and313, the springs 318 will move the parts to the right to normalposition. The cams 311 co-operating with the rollers 310, raise theclamp bar 300, so as to clamp the web 286 between the bar 300 and theupper clamp bar 306, and these cams are so designed that, while thisclamping action takes place, the clamp bars 300 and 306 are movedlaterally by the rocker arms 312, to eil'ect a feeding motion of theweb, it being understood that, while this occurs, the clamp bars 281 and290, will release the web, as shown in Fig. 9.

A bar 319 is mounted below the web 286, and guided for vertical movementbetween the guides 320 and 321. A stationary bar 322, above the web, isprovided with a steel-rule cutter or knife 323, co-operating with thebar 319, said cutter extending transversely of the web, but beingslightly shorter than the width of the web, so as to leave margins ateither edge which will not be engaged by this knife. The bar 322, whichcarries the knife, may be adjusted by means of screws 324 mounted in asupporting bar 325, and engaging the upper surface of the bar 322.Vertical motion is intermittently imparted to the bar 319, to force theweb 286 against the cutting edge of knife 323, by means of rocker arms326, pivoted on the rocker shaft 321, and carrying rollers 328 riding oncams 329 mounted on the cam shaft 299. These cams are so designed thatthe bar 319 will be forced upwardly to slit the web during the periodthat the web is being held against movement by clamping bars 281, 290,and released by the feeding bars 300 and 306.

Each of the plaiting bars 1\ 14 and '1 15, as shown in Figs. 7 and 9,has transverse knives 334 and 335 fastened to opposite ends thereof. Theknives 334 and 335 co-operate with a cutting bar 330 below the web 286,which is adjustably positioned with respect to stationary bar 331 byadjusting screws 332 mounted in the bar 331 and screwed into the bar330, spiral springs 333 surrounding the screws 332 being interposedbetween the cutting bar 330 and the stationary bar 331 to give theknives a yielding backing surface. The

flanged rollers 336 and 331, mounted on shaft 338,

and plain rollers 339 mounted on shaft 340, engage the edge portions ofthe web 286 and carry it away in the form of narrow ribbons of material,

after the strips have been severed from the web lay the strip-formingmechanism, and the plaiting It will be seen, therefore, that as the web208 6 passes through this mechanism, the clamping bars 281 and 290intermittently grip and release it. While such bars grip the web andhold it against movement, the clamp bars 300 and 306 release the web,and the cutting bar 319 is forced up- 10 wardly against the knife 323 toform a transverse slit in the web. When the cutting bar 319 descends,and the clamping bars 281 and 290 release the web, it is gripped by thefeed bars 300 and 306, which bars are moved to the left (Fig. 9), so as15 to give the web one step of forward feed equal to the width of theproposed separator strip to be formed. As the web leaves the slittingdevice, it will be seen to have a plurality of transverse slits therein,spaced a distance equal to the width 0 of the separator strips to beformed, and held together by the uncut margins of the web. The mechanismis so timed that, when the plaiting bar 115, for instance, descends tothe position shown in Fig. 2, the knives 334 and 335 on opposite ends 25of said bar engage the web 286 at the ends of one of the slits formed bythe knife 323, and cut the web, thus completing the severance of theseparator strip.

As shown in Figs. 7 and 8, both plaiting bars 30 114 and 115 areprovided with internal passages 342, communicating with smaller suctionpassages 341, which open through the lower surface of each bar. Pipes343 and 344 communicate, preferably through flexible hose connections,with a source of partial vacuum, whereby, at the moment the lower faceof the plaiting bar makes contact with the separator strip, which hasjust been or is being severed from web 286, the latter becomes attachedto the under surface of bar 115 by suction, so that the completelysevered separator strip 99, which has been cut from the web by theblades 334 and 335, is carried on the lower face of the plaiting barduring its return to the plaiting position. Referring further to Fig.'1, it will be seen that the'lower surface of each plaiting bar ispreferably provided with pins 345, projecting slightly from said lowersurface, so that the suction effect need only be sufficient to hold thestrip on the face of the plaiting bar during the return movement, whilethe pins 345 perforate the strip and insure against lateral displacementthereof during the plaiting operation.

Referring to Fig. 11, it will be seen that the plaiting bar 115 is shownin plaiting position. A separator strip 99 will be seen to be stillcarried by the lower surface of the bar 115, and, during the movement ofthe bar 115 to plaiting position, the separator strip 99 has moved overthe web 101, folding it over the upper surface of the separator strippreviously deposited, and moving the web to'the left, as shown in Fig.11, so that this web extends upwardly at the left of the plaiting bar115.

The plaited structure formed by the action of this plaiting mechanism isto be confined between the two parallel plates 146 and 141 duringseveral of the ensuing operations upon such structure. These plates arepreferably so mounted that the distance by which they are separated maybe adjusted. A series of lugs 148 and 149, carried by the plates 146 and141, respectively, near the upper edges thereof, support pins 150 and151, by which a series of levers 152 and 153 are pivotally connected tosaid lugs. These levers 75 carry a pair of jaw sections I54 and I56,which, as shown in Fig. 11, are in alinement with the upper portions ofthe plates I46 and I41. The levers I52 and I53 are provided with lugsI66 and I51, in which rollers I60 and I6I are journaled by pins I58 andI59. Cams I62 and I63, mounted on shafts I64 and I65, engage suchrollers with the result that, when the high portions of the cams bearagainst the rollers I60 and I6I, the jaw sections I54 and I55 are forcedtoward each other so as to clamp the plaited structure between them.When the low spots of the cams bear against the rollers I60 and I6I, thejaw sections I54 and I55 may separate slightly, so as to permit feedingmovement of the plaited structure between the jaw sections I54 and I55and in the passage defined between the plates I46 and I41. Lugs I66 andI61 formed on the jaw sections I54 and I55 carry pins I68 and I69, bywhich a series of detent fingers I10 and I'll are pivotally connected tosaid jaw members. The free ends of said fingers engage over the mouth ofthe passage formed by the jaw members I54 and I55, as shown in Fig. 11,and are so shaped that the downward movement of a plaiting bar, with aseparator strip attached thereto, will swing the fingers I10 and HI awayfrom the jaw members I54 and I55, sufficiently to allow the separatorstrip and the fibrous web to enter the mouth of the passage defined bysaid jaw members. Springs I12 and I13 are provided, secured to theplates I46 and I41 by the screws I14 and I15, which springs tend to holdthe fingers I10 and HI in the position shown in Fig. 11.

The plaiting bar II5 having just deposited a separator strip 99 in thepassage between the jaws I54 and I55, the cams I62 and I63 will nowrevolve so as to force the jaw sections toward each other, to clamp theplaited structure therebetween. As the plaiting bar II5 now rises, atthe beginning of its movement to the right (Fig. 2) to pick up anotherseparator strip, the plaited structure will be so securely grippedbetween the jaws I54 and I55 that the suction between the lower surfaceof bar 5 and separator strip 99 will be broken, and that separator stripwill be held between the jaws I54 and I55 while the bar II5 moves awaytherefrom. In the meanwhile, the left-hand plaiting bar II4 has pickedup a separator strip and moves from the dotted line position shown atthe left in Fig. 2, following the curved path there indicated, towardthe plaiting position. This movement causes the lower edge of plaitingbar H4, and of the separator strip 99 carried thereby, to engage the webIM and move it from left to right, folding it over the upper face of theseparator strip deposited by the bar H5, until plaiting bar H4 is inplaiting position. The separator strip carried thereby will rest on topof the web WI, and said web will extend upwardly to the right of theplaiting bar I I4. Thus, the to and fro movement of the plaiting frame,and the bars H4 and H5 carried thereby, will pick up separator strips,deposit them one by one in position, and fold the web IOI back and forthbetween and around the edges thereof, forming the plaited structureshown in the upper portion of Fig. 11, between the jaw sections I54 andI55. The fingers I10 and "I will be forced aside by the descendingseparator strip 99, but, since such strips are slightly wider than theplaiting bar, the fingers I10 and I1 I, together with the clampingaction of the jaws I54 and I55, will detach the separator strip from theplaiting bar, when such bar leaves plaiting posiposlte faces of theplaited structure and this step may be carried out by the use oi. thedevices which I will now describe. Referring to Figs. 12 and 13, it willbe seen that the plates I46 and I41, between which the plaited structureis confined, are cut away to form the openings I16, I11, I18, I19 andI80, and the lower edges of the plates I46 and I41 are sloping, as shownin Fig. 13. Below the plates I46 and I41 are the parallel plates I82 andI83, defining between them a continuation of the passage in which theplaited structure moves. The upper edges of the plates 20 I82 and I83are also sloping, as shown in Fig. 13 and separated from the lower edgesof plates I46 and I41 by the diagonal slots I84 and I85. These slotsexpose both faces of the plaited structure to the action of rubberizingmechanisms, which 25 are provided in duplicate, one at each face of theplaited structure, and which reciprocate to and fro longitudinally ofthe slots I84 and I85. Each rubberizing mechanism comprises a suitablymounted friction roller I86 and spray nozzles I81 and I88, arranged foreand aft of the roller, and connected with a source of supply ofcementing material, such as rubber latex, or a compound thereof, wherebythe nozzles spray this cement on the exposed surfaces of the plaitedstructure, and it is frictioned on by the movement of the roller I86thereover.

As the now cemented plaited structure continues its passage between theplates I82 and I83, it is dried by warm air. To this end, castings I90and I9I are applied to the plates I82 and I83, in which castings thereare cored out the supply passages I92 and I93 and the exhaust passagesI94 and I95. These diagonal passages register with correspondingdiagonal slots in the plates I82 and I83. Supply pipes I96 and I98, forexample, communicate with opposite ends of the supply passages in thecasting I90, while supply pipes I91 and I99 communicate at opposite endswith the corresponding supply passages in the casting I9I. Warm air issupplied through these supply pipes and passes through the supplypassages in the castings, through the plaited structure confined betweenthe plates I82 and I83, and passes out through the exhaust passages I94and I95. Thus, a cementing material, which has been applied to oppositefaces of the plaited structure, is dried. The lower sections of platesI82 and I83 may, if desired, be cut away to form openings 200, 20I, 202,203 and 204.

Slightly below the drying apparatus, transverse slots 220 and HI areformed in the plates I82 and I83, through which slots the webs 208 and209 of cemented base fabric are applied to opposite faces of the plaitedstructure. This cemented base fabric is supplied from the rolls 206 and201 and passes around the idler rollers 2I0 and 2H and the let-offrollers 2I2 and 2I3, the latter being preferably clothed with a frictionmaterial, such as card-clothing. From the let-off rollers the websof-cemented base fabric pass over the guide and pressure rollers 2I8 and2I9 to the faces of the plaited structure, said pressure rollers 2I8 and2I9 being so mounted as to revolve in the slots 220 and HI, so as topress the cemented fabric against opposite faces of the plaitedstructure. It will be seen, therefore, that, as the material leaves therollers 2I8 and H9, it comprises the plaited structure, including theseparator strips, the fibrous web wound back and forth about saidstrips, and the backing sheets 288 and 269 cemented to the fibersexposed at opposite faces of said plaited structure.

The next step consists in consolidating and vulcanizing the compositematerial so formed, and this step is carried out in the press, to whichthe material goes from the rollers 2| 8 and 2l9.

This press is shown in Fig. 1a, in side elevation.

It comprises a rectangular base plate 222, having a slot therein throughwhich the material passes, and lugs at the four corners thereof, inwhich are mounted four posts, two of which, 224 and 225, are shown inFig. 1a. The four posts are held in parallelism by the end casting 226and serve as supports for the fixed frames 221 and 228, and also asguides for the movable frames 229, 230, 23l and 232. The movable frames229 and 230 are tied together by a platen 233 carried thereby, ofsubstantially the width of the material to be treated, and by a plate234 which serves as a support for the hydraulic rams 235 and 236, whosepiston rods 238 and 239 are attached to movable platen 246 co-operatingwith the platen 233. Similarly, the movable frames 23I and 232 are tiedtogether by a platen 241 and a plate 242, which serves as a support fora hydraulic ram 243, whose piston rod 244 is attached to a movableplaten 245. A hydraulic cylinder 246, mounted on a lug 241 on the fixedframe member 221, is connected by a piston rod 248 with a lug 249 on themovable frame 230. Similarly, a hydraulic ,cylinder 250, mounted on alug 25l on the fixed frame 228, is connected by its piston rod 252 withthe lug 253 on the movable frame 232. Sufllcient pressure is applied tothe movable frames 238 and 232, by the hydraulic cylinders 246 and 256,to nearly counterbalance the weight of such frames and the parts carriedthereby, so that little work is required to shift such frames along theguide posts 224 and 225 by the cam means to be described.

It will appear, from the foregoing, that the movable frames 229 and 230,connected by the platen 233 and plate 234, carrying the hydraulic rams235 and 236 for the movable platen 246, constitute a press unit which isvertically movable on the posts 224 and 225. Also, the movable frames23! and 232, connected by the platen 241 and the plate 242 carrying thehydraulic ram 243 for movable platen 245, constitute another press unit,also vertically movable on the posts 224 and 225. The fixed frame member221 is provided with lugs 254 and 255, which support shafts 256 and 251,on which are mounted the cams 258 and 259, contacting with rollers 2166and 261, which are journaled in lugs 262 and 263 on the movable framemember 229. As the shafts 256 and 251 revolve, therefore, the frame 229,.and the press unit carried thereby, are slowly permitted to descend andthen quickly raised to the position shown in Fig. 111. Similarly, thefixed frame 228 is provided with lugs 264 and 265, which support shafts266 and 261, on which are mounted the cams 268 and 269 contacting withrollers 216 and 2H, journaled in lugs 212 and 213 carried by the movableframe 23l. As the shafts 266 and 261 revolve, the frame 23l will bequickly raised to the upper position by cams 268 and 269, and thenpermitted to descend slowly. It will be observed that the cams are somounted that the lower press unit is descending slowly, while the upperpress unit is being quickly raised to the upper position. The cam shafts256, 251, 266 and 261 may be positively connected, by any suitablemeans, with the shaft I45, so that the downward movements of the pressunits, when engaged in pressure contact with the material, maycorrespond exactly with the rate of feed of such plaited material. Thecam pairs 258, 259, 268 and 269 are so related to each other, and thevalves controlling the supply of water to the hydraulic rams 235, 236and 243, are so operated mechanically, in the well known manner, by thevertical movement of the asso ciated press units that, when either ofthe press units is descending, its platens are in pressure contact withthe material between them, while the platens of the ascending unit areout of contact with the material between them. The result of thisco-relation between the mechanisms for operating the press units is thatthe material is being pressed and vulcanized constantly, and the activepress unit is controllably moved down at a rate corresponding exactlywith the rate at which the plaited material is being formed. Thehydraulic cylinders 246 and 256 are constantly supplied with water underpressure, and, as previously stated, are so proportioned as to relievethe cams 258, 259, 268 and 269 of practically the entire work of raisingthe corresponding press unit.

When the plaited material emerges from the lower end of the press, justdescribed, with the backing sheets 288 and 269 cemented and vulcanizedto both faces thereof, it is ready to be split longitudinally, along aplane parallel to opposite faces of said material, to remove theseparator strips and form two continuous webs of cemented pile fabric. Iprefer to accomplish this by the splitting device illustrated in Fig.14. The web 214 of material, as it comes from the press shown in Fig.1a, passes between guide rollers 216 and 211 and is split by aband-knife 218, which moves between stationary guides 280 and 281. Thisknife not only splits the fibers, which are secured to and extend fromone backing sheet to the other, but also splits the severable chipboardseparator strips 99, thus splitting the web 214 as it comes from thevulcanizing press into two webs of cemented pile fabric, which are woundinto rolls 282 and 283, upon shells 284 and 265, on shafts 286 and 281,which may be driven frictionally in a well-known manner.

The pile fabric wound upon the shells 284 and 285, as it emerges fromthe lower end of the machine, may be subjected to further finishingoperations. The separator strips 99, having been severed by the knife218, may drop out as the fabric is rolled upon the shells 284 and 285,but, to make sure that such strips are all removed, the fabric, pileside down and under moderate tension, is passed beneath and in contactwith a rapidly revolving beater roll, not shown, consisting of a hubbearing a number of radially projecting blades of equal length. Thisbeating operation causes the greater proportion of the split separatorstrips to fall out of the pile. The pile fabric is then subjected to atigering operation for the removal of short and unattached fibers. Inthis operation, the goods are carried under tension, pile surface up,over a cloth rest, as in the well known form of cloth shear. This causesthe pile to grin and, while it is thus open, it is raked by a rapidlyrevolving roller clothed with garnet wire. This positively removes anyseparator strips, which have not been removed previously, and combs thepile fibers into substantial parallelism. Thereafter, the goods may bebrushed and sheared, as required to level the pile surface to thedesired extent.

The consecutive steps of the method disclosed herein are indicated bythe fiow sheet forming Fig. 16. It will be seen that, starting with thefibrous web, a warp of spun yarns, or a bat of unspun fibers, if such isused, the web is continuously looped, folding it back and forth aroundseverable separator strips, which, in the particular machineillustrated, are formed in the machine from a web of suitable material,such as chip-board. The fibrous web having been continuously loopedaround the separator strips, the opposite sides of the plaited structurehave cementing material applied thereto and the structure is then dried,after which webs of cemented base fabric are applied to opposite facesof the plaited structure, and the material is subjected to consolidationand vulcanizing by the pressing operation. After this step, the materialis split into two webs of cemented pile fabric, which operation alsosplits the separator strips, and renders possible their removal.Thereafter, the webs of pile fabric may be subjected to beating,tigering and shearing operations, if desired.

The way in which my improved method may be carried out by the mechanismand apparatus herein described should be apparent from the foregoing,but will be briefly reviewed at this point. Cam shaft I65 turns at twicethe speed of shaft I26, so that, for each complete reciprocation of theplaiting frame, guides H6 and III will be subjected to two completevertical reciprocations. Consequently, the frame H3, and the plaitingbars HI and H5 carried thereby, will travel in the paths indicated bydotted lines in Fig. 2. In this figure, the plaiting bar IN is shown inthe mouth of the passage defined by the jaw members I54 and I55, havingjust deposited a separator strip above the web IOI therein. The bar H4now rises and moves to the left, toward the dotted line position, and atthe same time the bar H5, which has severed from web 286, and picked up,a separator strip 99, rises and moves to the left, following the curvedpath indicated. In so doing, the separator strip carried thereby engagesthe web IM and pushes it to the left over the previously depositedseparator strip, the bar H5 finally moving into the mouth of the passagebetween the jaw members I56 and I55 and depositing the separator strip,which it carries, upon the web IIII therein. Thus, the to and fromovement of the frame H3 picks up and deposits separator strips 90 inthe passage and folds the fibrous web I M back and forth about saidseparator strips, as best shown in Fig. 11. In completing its downwardmovement in the formation of a plait, each plaiting bar passes betweenthe fingers I10 and III, which are sprung apart by the passage of theseparator strip, purposely made of somewhat greater width than the faceof the plaiting bar. After the passage of the strip, the fingers I70 andI'll are instantly returned by the springs I72 and I13 to the positionshown in Fig. 11. As each plaiting bar brings the strip fiush with theopening between the jaw sections, the cams I62 and I63 present their lowspots to the cam rollers I60 and I6I, allowing a slight separation ofthe jaw sections I54 and I55, so as to permit the included plaitedstructure, in response to the thrust of the plaiting bar, to movedownward a distance corresponding to the thickness of the newly formedplait. The cams I62 and I63 are so designed that the jaw sections arethus relaxed only during the brief period when a plaiting bar is in theapproximate position shown in Fig, 11. At all other times during theplaiting cycle, the jaw sections are firmly pressed against the plaitedmateriahso that the fingers I10 and III are relieved of any otherfunction than that of preventing the escape of the plait last formed.

The rollers I04 and I05, which support the roll I00, may be adjustablyor variably connected, in any well known manner, with the shaft I65(Figs. 4 and 5), so as to cause rotation of the roll I00 at the constantsurface speed necessary to supply the web IOI at the exact speedrequired by the continuously looping operation. Similarly, a frictiondrive of any well known form may serve to wind the wrapper I02 on theshell I06 at the same linear speed. When I use my improved method forforming a cemented pile fabric from a warp of spun yarns, using thefeeding arrangement shown in Fig. 3, the continuously looping operationdraws the warp through the comb I I2, the friction bars I09, H0 and IIIserving, together with the inertia of the warp wound on the beam I08, tomaintain a suitable tension.

In describing the strip-forming mechanism, we have also explained,somewhat, its operation.

The strips are preferably formed from a web 286 strip. While the web isgripped and held against movement, the cutting bar 3I9 rises against theknife 323 and forms a transverse slit in the web. When the web issubsequently fed across the cutting bar 330, the plaiting bar H4 or II5,as the case may be, descends, and the knives 33d and 335 carried therebyform transverse cuts in the web, at the ends of the slit, thuscompleting the severance of a separator strip from the web, and, at thesame time, the severed strip thus formed is perforated by the pins 345on the lower face of the plaiting bar, and held to such bar by suction,while the bar travels from the cutting position to the plaitingposition. Thus, during each cycle of movement of a plaiting bar, itsevers a separator strip from the web and carries the severed strip tothe plaiting position, where it is deposited in the entrance of thepassage formed between the jaw members I54 and I55.

The various controlling cams for the stripforming mechanism are soshaped and mounted on the shaft 299, and the latter is so connected thestrips to the exact width required, and so as to present the slit web atthe proper point to the plaiting bar for final cutting and removal.Desired variations in the widths of the strips, as required for materialof difierent pile heights, may be secured by the substitution of cams 3Mof appropriate contour. Similar apparatus arranged at the opposite sideof the machine, for cooperation with plaiting bar I I4, performs exactlyanalogous functions with respect to a similar web 286, from whichseparator strips are formed to be picked up by the plaiting bar I I6 anddeposited in the plaited structure.

In commencing the continuously looping operation, with no previouslyplaited material in the apparatus, it is necessary to provide atemporary support for the plaited material until the coated base fabricshave been applied, and the resulting material emerges from between theplates I82 and I83 preparatory to being pressed and vulcanized.Referring to Fig. 15, interconnected screw shafts 348 and 34'! mountedin frame lugs, 348, 348, 350 and 35I, are operated to bring the nuts 352and 353 thereon to a position approximating in height that of the jawsections I54 and I55. A temporary support 356, of a thickness somewhatless than the distance separating the plates I46 and I41, is insertedbetween the jaw sections and the adjacent plates and is attached to thenuts 352 and 353 by pins 354 and 355. By means of any suitable clutchmechanism, the interconnected shafts 346 and 34'! are rotated from theshaft I45 and the plaiting operation is commenced. By the introductionof variable gearing in making the foregoing connection, the temporarysupport 356 may be made to descend at a rate corresponding to theparticular number of plaits per unit of length, which it is desired toproduce. When the temporary support 355 has descended to the lower endsof plates I82 and I83, the pins 354 and 355 may be removed, the shafts346 and 341 disconnected from the drive, and the temporary support 356removed, as there is now sufficient plaited material in the machine tosupport the plaits as they are formed.

As the plaited material advances through the machine, between plates I46and 1, the rubberizing mechanisms, working in slots I84 and I85, spray acementing material on the opposite exposed faces of the plaited.structure, and friction it in. As this cemented material passes onbetween the plates I82 and I83, it is exposed to the drying effect ofwarm air introduced through the supply pipes and passing through thematerial to the corresponding exhaust passages. The slowly moving massof cemented material is thus exposed to the alternate passage of hot airfrom opposite sides, which very effectively removes the volatilematerial from the applied cement. When the dried material reaches theslots 220 and HI, its cemented surfaces are brought by the pressurerollers 2! and 2i 9 into contact with the previously cemented webs ofbase fabric 208 and 209, which are thus united to opposite faces of suchmaterial. Shafts 2I4 and. 2I5 are connected, in any suitable manner,with the shaft I45, so that the surface speed of the rollers 2I2 and H3may determine the speed at which the base fabrics are supplied, thusregulating the passage of material to the press to the rate at which theplaited material is being formed in the machine. The material now passesfrom between the plates I82 and I83 to the press unit, which alternatelygrip the material to apply a consolidating and vulcanizing pressurethereto, and release the same. The upper unit is shown, in Fig. id, asreleased and about to rise, while the lower unit is applying pressure tothe web of material and is about to descend slowly at a ratecorresponding to the rate of movement of the material through themachine. When the lower press unit is released, the upper press unitwill be in position to apply pressure and move downwardly at the saidrate. When the material leaves the consolidating and vulcanizing press,it is split into two webs of cemented pile fabric by the knife 218 shownin Fig. 14.

It will be evident that the method herein described is relativelyinexpensive, as compared with methods heretofore used for the productionof cemented pile fabric. Consequently, by the use of the method hereshown, the cost of production will be lowered. Since two webs ofcemented pile fabric are simultaneously produced, the speed 01'production is greatly increased. This also helps to cut the cost. The

material produced by this method will be of improved quality, since thepile surface of the fabric will be perfectly smooth, and without any"ripple, which heretofore has caused considerable trouble in theproduction of cemented pile fabric of this character. The method lendsitself readily to simple and inexpensive adjustments, by which to varythe characteristics of the pile fabric produced thereby. Furthermore,the use of severable separator strips not only makes their eliminationfrom the structure much simpler, but also is an advantage in thepressing operation, since pressure is there applied to a relativelyyielding structure.

I am aware that the particular embodiment of my invention, hereillustrated, is susceptible of considerable variation without departingfrom the spirit thereof, and, therefore, I claim my invention broadly,as indicated by the appended claims.

What I claim is:

l. The method of making cemented pile fabric comprising continuouslylooping a fibrous web about a series of severable separator strips toform a plaited structure, cementing webs of base fabric to oppositefaces of said plaited structure and splitting said structure includingthe separator strips along a plane parallel to said base fabric to formtwo webs of cemented pile fabric therefrom.

2. The method of making cemented pile fabric comprising the continuouslooping of a web of unspun fibers about a series of severable separatorstrips to form a plaited structure, cementing webs of base fabric toopposite faces of said plaited structure and splitting said structureincluding the separator strips along a plane parallel to said basefabric to form two webs of cemented pile fabric therefrom.

3. The method of making cemented pile fabric comprising the continuouslooping of a warp of spun yarns about a series'of severable separatorstrips to form a plaited structure, cementing webs of base fabric toopposite faces of said plaited structure and splitting said structureincluding the separator strips along a plane parallel to said basefabric to form two webs of cemented pile fabric therefrom.

4. The method of making cemented pile fabric comprising the continuouslooping of a fibrous web about a series of severable separator strips toform a plaited structure, cementing the webs of base fabric to oppositefaces of said plaited structure, splitting said plaited structure,including the severable separator strips, along a plane parallel to thebase fabric to form two webs of cemented pile fabric therefrom, andremoving the split separator strips.

5. The method of making cemented pile fabric comprising the continuouslooping of a fibrous web about a series of severable separator strips toform a plaited structure, cementing a base fabric to one face of saidplaited structure, splitting said structure, including the severableseparator strips, along a plane parallel to the faces thereof, andremoving said split strips.

6. The method of making cemented pile fabric comprising the continuouslooping 01' a fibrous web about a series 01 severable separator stripsto form a plaited structure, applying webs of base fabric to oppositeiaces 0! said plaited structure.

. subjecting the coated structure to pressure to consolidate the same,splitting said structure, including the severable separator strips,along a plane parallel to opposite faces thereof, and removing the splitstrips.

'7. The method of making cemented pile fabric comprising the continuouslooping of a fibrous web about a series of sever-able separator stripsto form a piaited structure, apnly ns a coating of rubber cement toopposite faces of said structure, applying coated webs of base fabric toopposite iaces of said structure, subjecting said coated structure topressure to consolidate and vulcanize the same, splitting saidstructure, including the severable separator strips, along a planeparallel to oppoflte faces thereof and removing the split strips.

, PAUL 8. SMITH.

